Modified phenolic resin



Patented Oct. 26, 1954 2,692,865 oomnso PIHENIOLIC RESIN Thomas G. Harris, Coopersburg, Pa., assignor to *Catalin Corporation oil America, a corporation of=Delawarew a Nb Drawing. Application June 26, 1951,

$3M- SeriaPNo. 233,680

This invention relates to modified phenolic resins and the method of making them. The

invention relates particularly 'to be'ta-propio1ac tone modification of phenol and formaldehyde condensation products and like modification or otherphenolic resins. i

The lactones are to be distinguished from ethylene oxide and other epoxy compounds, the

use oiwhich in modifying phenol aldehyde resins is describedin my copending' applicationSerial No. 2011882 filedDecember-2011950; for Epoxy Modified Phenolic Resin. diffi'cultyarises when it is attempted to follow the general procedure 'of the said copending application but with the substitution of the lactone for the epoxy compound. The lactone, when used in proportion that is large orequivalent to the phenol-aIdehyd'e conden'sation product and withthe' usual'small catalytic proportion of an allrali, gives the'desired modification only to a' limited extent. -The 1111- used lactone then enters into' 'undes'ired side reactions" with water, methanol introduced with the commercial solution 'of formaldehyde, or

other reactiveco'mpound that'maybe in th'e'mix-" .ture. The product in sucha case is a' 'liduid'or softresin; I 5''? The present invention provides a solution of this difiiculty. It provides an'ieth'ocl in' which the lactone is 'reactedin various pro'pbr'tioriSiip to approximately stoichiometric with the phenol formaldehyde condensation product? The invention provides for the production" atwill'of either a solid modification product-Oraliduidproduct usually of lesser modification by the lactone. The solid product is useful-as a molding plastic or powder, "an ion exchange resin, or 'aplasticizer intermediate. The liquid pr'oduc t is usef lil 'in making castresi'ns; asan adhesive; or as a plasticizer for other resins.

Briefly stated, the invention comprises lactone modified phenol aldehyde condensatiodproducts and the method of efiectin'g thelactone modification. In effecting the modification "to" the advanced stage desirablefor'manwpurposes', the invention comprises adding an alkali in relatively large amount. The alka'limay' be added-anther beginning of the modification or ""as'"reduired"to neutralize acidity as i it" develops, during the modification, and maintain the'pH-at all times at a level of at least 4 and, when a solid resin is desired, preferably at or above 7, until the modification is effected. in one ei'nbodimentfthe invention comprises esters of the modified product, as, for example, esters of a monohydric or polyhydric alcohol with the laotone modified phenol and aldehyde condensation-product. As to the method of effecting the lactone modification, the selected phenol and selected aldehyde are condensed in accordance with usual technique in the condensation of phenols with aldehydes. In such condensation, there-is ordinarily employed either alkali or acid catalyst.

For my modification with lactone, the usual condensation of the phenol and the aldehyde is interrupted as at the stage when the content of free aldehyde ceasesto fall rapldlyand before the subsequent rapid onset of viscosity or thick ening'of the mass which accompanies continued condensation. This interruption is effected by introducing the selected lactone and alkali in amount if any required to establish the pH above 7: Additional alkali is added from time to time if'required to maintain the pI-I at a levelabove 1 atall times during the modification ofthe lacone. 1

Under such favorable circumstances, the lactone enters the hydroxyl group of the phenol. This reaction'creates in the modified product a carb'oxyl group which reacts with the alkali added.

So' long as the proportion of alkali is adequatc, there is an absence of extensive and undesired side reactions. In fact 'the'composition may be slightly acidified by the addition of acid in making liquid or cast resins.

This reaction which causes the desired modification occurs at room temperatures. In some instances, warming, as for half an hour or so under refluxing or at a somewhat lower temperature is employed, to promote modificationat a 001m mercially satisfactory rate;

The reaction may be represented by the following equation, for the modification of the phenol formaldehyde condensation product with beta-propiolactone:

Phenol formaldehyde resin unit 3 p,p-dihydroxydiphenyl propane, metacresol, pyrogallol and guaiacol. Some of these are monohydric and others polyhydric phenols.

In this equation, equivalent proportions are used. The general average formula of the ixed product, for various proportions of lactone used may be represented as The value of y in the above formula unit is dependent upon the initial mol ratio of phenol to aldehyde and upon the type of catalyst employed in the condensation step. 11 represents a value between and 1; it, an integral number at least 1 (for the monomer) and considered to be 3 to 20 corresponding to the number of the monomer units (inside the parenthesis) combined in the polymer constituting the resinous composition; and a2, a number not greater than 1. While n represents an integral number for any specific compound in my product, it will be understood that in all such polymeric resinous materials there is a mixture of various compounds, so that the average value of n is not necessarily integral for the entire mixture. In any case the average value of n in my product is considered, as stated, to be not less than 3. In the product in which all the phenolic hydroxyls have been reacted with beta-propiolactone, :c is 1. Such a product may be considered a high molecular weight polyacid. A low value of y in the formula minimizes the possibility of interor intra-esterification of the methylol group (CH2OH) and the acid group (-COOH). The products from Examples 1, 2, and 3 later herein, while thermoplastic, can conceivably thermoset on their own accord at higher temperatures through this mechanism.

The aldehyde used is one that is water soluble and reactive with phenol under the usual conditions of aldehyde and phenol condensation. I have used to advantage various aldehydes of this class, including formaldehyde, paraformaldehyde, 'or other formaldehyde polymer, either with or without the inclusion of the methanol which occurs in some commercial formaldehyde solutions to the extent of about furfural;

and glyoxal.

The lactones that are useful in the present composition and process are those that are miscible with the aqueous phenolic resin mix. The betalactones are preferred because of good reactivity under my conditions. Examples of these that are satisfactory for my purpose are beta-propiolaczone, beta-butyrolactone, and beta-isobutylrolacone.

The alkali used in the modification serves actually as a reactant. I may use any one of the inexpensive alkalies such as an alkali metal hydroxide, calcium hydroxide, and amines of which examples are monoethylamine in solution and quaternary ammonium compounds, as, for instance, benzyl trimethyl ammonium hydroxide. It will be understood that these alkalies may be replaced for sodium hydroxide in the equation above in equivalent proportion. If R is the cation of the alkali, R may be substituted for Na in the equation and Na or R for the acid hydrogen in the formula. The formula including the acid hydrogen is used by me for convenience as it represents my resinous product aiter acidific tion.

I find no advantage in using generally the more expensive alkalies over using sodium hydroxide. As a result I use sodium hydroxide as the alkali except in the preparation of certain cast resins where other alkalies are used for their known advantages, as in imparting to the cast resin certain special properties such as improved light transmission.

Water is useful in the reaction mixture. It promotes ionization of the phenol in the presence of the alkali and for that reason promotes reaction of the lactone with the phenolic hydroxyl group.

Other materials ordinarily introduced into plastics for their known effects may be used in my modified product as, for example, pigments, fillers, and the like.

As to proportions of materials, these are expressed herein as mols per mol of the selected phenol unless otherwise specifically stated.

The proportion of the selected aldehyde to the selected phenol may be any that is conventional in the manufacture of phenol and aldehyde condensation products as for instance 0.6 to 3.5 mols of the formaldehyde to 1 of the phenol. When the phenol selected is monohydric then the ratio of the aldehyde, particularly when the aldehyde is formaldehyde, is ordinarily within the range 0.8 mol to 2.5 mols for 1 of the phenol.

PROPORTION OF THE BETA-LACTONE AND TIME or INTRODUCTION INTo THE CONDENSATION PRODUCT The beta-lactone is used in the proportion of about 0.1 to 1 mol for each mol of the phenol when monohydric. When less than 0.1 mol of the lactone is used, the modification produced is not sufiiciently extensive. When the proportion of the lactone is more than 1 mol, then there is an excess which does not react with the phenol according to the principal and desired reaction given above. Larger amounts than 1 mol of the lactone may be used if there is no objection to by-products in the finished resin. While I use ordinarily no substantial excess of the lactone over that which I desire to have in the finished modified product, I may use an excess ranging up to or so of the lactone above the proportion to be reacted. When the phenol is polyhydric, then the molecular proportion of the lactone is increased to correspond, as, for example, to an amount within the range 0.1 mol to 2 mols with a dihydric phenol. With a trihydric phenol, the proportion of the lactone may be as high as 3 mols to 1 of the phenol in addition to any excess of the lactone that may be added.

The effect of the proportion of the lactone on the properties of castings prepared from the modified resin is shown in the table below, the phenol and formaldehyde having been used in making the original condensation product in the ratio of 1 mol to 2.32 respectively and sodium hydroxide being used in the modification step in the proportion of 3% of the weight of the phenol. In this table and elsewhere the yield is expressed as parts by weight for 1 part of phenol.

Mols beta-propiopH of the Time of Rockwell lactone added per modified Yield Cure at Hardness mol phenol system 0. of casting Hrs. 6. 22 l. 88 42 +71 5. 35 1. 92 42 +35 5. 07 1.98 42 0 0.36 4. 90 2. 04 42 10 This effect on finished castings is shown again in' the: next table; the basiwresinpeleeted here formodification haying-bee prepared ;from p,p-- dihydroxydiphenylpropanej,1

formaldehyde ,(methanoleifree) 1; 3,65. l The con densati'on was eflected for seven minutes. at reflux.u The. catalyst :wassodium-hydrogiide (6.0

by weight onthe phenol T modification by the .lactonejwas made at end: of thetinitial al Light transmission is stated herein, in the order ofincreasing transmissibility as'followsr Opaque Poorly opaque Heavily translucent Translucent Lightly translucent Poorlytransparentf Transparent (s1. haze) Transparent The effect of the extent of modification on fim;

ished 1 castings is illustrated still further by t succeeding tables.

l Phenol-formaldehyde cast" ;resin-. Mol ratioofj.

phenol to formaldehyde; (methanol; stabilizer) l 2.32. CQIldQIlSfitiOIlfiGVBlltSIl;mllllltes at ree t sd m-h dri2 i e 3%; by e h on phenoD-u Modificationfiafterweak acidifica: tion.

M015 sea rune- Roclllr propw' Pouring we Light tr ans lactone L Yield ,Cure Hardi. added per V130" at 90 ness of mlsslblhity mol' phenol Castmg.

HTS." I i I 0.22 almost 1101'- 1.95 72 +48 heavily transmal. lucent. thin 2.07 72 4 translucent. normal 2.181. 721' i 37 transparent.

2.28 72 s0 Do.

Phenol-formaldehyde cast' resim- Moi ratioof phenol to formaldehydewmethanol stabilizer) 1:2.32. Condensationse venteen minutes at reflux. catalyst sodium' hydroxide (3% by weight on phenol) Modification at eer condensation. Glycerine present. The summary and results follow.

Mols beta- Time PmPlo' pH of of Rockw,e11 w lactone Modified Yield. Cure H rdness of gfi fi added par System at90 Easting- 1111551 1 y mol p e C" nol Hrs. 0.09 6.23 1. s5 4 2 P or i s- .W QI F 0.18;.-;. 5. 40. 1.93 i 42 16 transparent (sl. haze). 0.27. 5.06 1.98 42 39. transparent. 0.36 4.96 2. 075 42 toonsoft. ,to Do. measure.

the: P 16 1 2 nd l formaldehydein .the mol ratio of; the phenol to r Phenol-formaldehyde cast resin. Mol ratio of phenol to formaldehyde. (methanol samurai);

122.32. Condensation-seventeen minutes at reflux. Catalyst-sodium hydroxide (3% by weight erine present. The summary and results follow.

Mols beta- Time propioof Rockwell lactone Pouring Yield vCure Hardness Light transaclded Vise. at of missibility per. mol. Casting phenol: 0.

Hrs. 0.00 s1. thin;- 1.93 44 +12 opaque. 0.06 do; 1.93 44 +8 very heavily,

translucent. 0.12 44 0 Do. 0.21 44 -26 lightly translucent. 0.30 thin 2.10 44 +58 transparent az 0.39 v.sl.thin 2.17 44 too soft to transparent.

. read...

While these and the other ones of the extensivetables and examples herein are. not necessary for an understanding of the invention, they should be of interestrtothe technical worker in this field.

It canbe concluded from the preceding tables that, as the amount of beta-propiolactone in creases; usually 1 (1) The pH of the system decreases,

(2) the pouring viscosity decreases,

(3) the yield increases,

(4) the hardness of casting is lower per unit curing time, and l l (5) the light transmissibility of casting becomes greater.

The thinning of the viscosity is of particular value where intricately designed molds are employed. Another suggested use based on this lyst, methylol phenols form almost immediately.

These'jrnethylol phenols act as nuclei for subsequent condensation. The presence of a large number of nuclei early in the reaction favors the formation of many relatively short chains of approximately the same length. Therefore, when beta-propiolactone is introduced in one portion in sufficient amount to react completely with the phenolic hydroxyls, the product originating consistsof chains, the molecular weights of which fall within a relatively narrower range than if addition is performed gradually or intermittently. A similar effect to the latter can be obtained by mixing resins which had previously been modified after different times of condensation.

The chains forming as the dimethylol phenols condense gradually increase in length as the time of condensation is prolonged. This accounts for the different products formed when variations in the details of addition are employed.

Furthermore, as condensation proceeds the percentage of free formaldehyde decreases (rapidly at first) and finally attains av yalue which changes only very slowly with further condensation, as shown in the table. 1 1

Time from Percentage start of free formreflux, aldehyde min. (by wt.)

Time from first application of heat, mins. Remarks The addition of the beta-propio l a c t o n e is usually made 1) e y o n d t h is point.

The exact proportion at which the free formaldehyde content will begin to level ofi is influenced by a number of factors as, for example, the phenol-formaldehyde mol ratio, the amount of catalyst, and other factors as illustrated in the following table.

[Catalystz Sodium hydroxide (3% based on phenol)] Percentage Phenol formaldehyde mol ratio gff ggfj b levels oil at- [Phenol formaldehyde mol ratio:1:2.32]

Percentage free formalde- Sodium hydroxide catalyst based on phenol, percent gg g g g percent HOHO The beta-propiolactone is usually introduced after the free formaldehyde content has approached or reached the leveling off value and before the rapid onset of viscosity of the resin or thickening has begun.

500 gms. phenol.

1,000 gins. formaldehyde solution (37%, aqueous, methanol-free). 60 gms. sodium hydroxide solution (25%, aqueous).

\ I is reached.

The average molecular weight of the product will naturally be greater, the longer the condensation time preceding the beta-propiolactone addition.

pH of the modified Mols beta-propiolactcne added per mol phenol solution It will be observed that the lactone in excess of 1 mol has no efiect in further lowering of the pH and actually caused a slight increase in this set of preparations.

EFFECT or PROPORTION or ALKALI UsEo As to the proportion of alkali, this varies as stated in accordance with the extent of modification desired. When it is desired to make a solid product, I use the alkali in amount to maintain the pH on the alkaline side (above pH '7) at all times during the modification and that requires about 1 mol of the sodium hydroxide for each mol of the lactone to be reacted with the phenol. When the effect of the extensive modification or a solid product is not desired, then the proportion of alkali as well as of lactone may be lowered, as,

for instance, to any propo-rtion within the range 0.1-1 mol. In making liquid or cast resins, I may use the alkali in amout to maintain the pH during the lactone modification at 4 or above.

EFFECT OF WATER ON THE MODIFICATION (a) Provides an ionization medium directing the reaction toward the phenolic hydroxyl groups under basic conditions, and

(1)) Aids in the dissipation of the exothermic heat providing thereby adequate control.

THE METHOD IN GENERAL In making my new resin, phenol and formaldehyde are reacted (condensed) in the ratio of 1 mol of the former to about 0.8-2.5 mols of the latter, with an alkali or other suitable catalyst at a temperature between 50 C. and the reflux temperature of the mixture, and until the free formaldehyde content has ceased to fall rapidly. When that stage has been reached, while the phenol formaldehyde condensation product is in a water soluble form as shown in Example 1, and before the rapid onset of viscosity that comes when the condensation is continued, beta-propiolactone is introduced in amount ranging from 0.1 to 1 mol or somewhat more, the exact proportion of the lactone used depending upon the spe cific properties desired in the finished product, the larger the proportion used the greater the modification of the phenolic resin and an excess estates of C the lactone I being permissible. The betapropiolactone' may serve a the sole acidifying agent as the 'reaction'progressesor further acidification may be made by the addition of lacticpr other acid commonly used as an acidifying agent of 3 phenol-formaldehyde "composi ons. After modification, the product if solid is separated in usual manner asby filtration. I: more; the pr fuuct isdehydrated by eva oratif reduced pressurej, til therein water practically ceases. For casting the l qu d resin is poured into, a ,moldand cured at a temperature of 75 to 90 'Cf. for the time determined by simple tests to be necessary toeifect the cure, as, for example, for about 1 day to 5 days.

When the phenolmsd is one such' asfa dihydroXy diphenyl alkarle, with an active. hydroxy group on each of the benzene rings, a larger proportion of the formaldehyde may be used as illustrated in Example 3.

In making solid products 'by this method a large proportion of alkali i's'int'rodiiced, to maintain the pH at about or above 7. I 1 m Other variations are theladdition of"pigments,

a polyhydric alcohol 'such as glyceri e, a monohydric alcohol such as methanoljjorsalts.

Another phenol, as, for example,- p',p'"-dihydroxydiphenylpropane,orany other one of those listed above may besubstituted for the phenol in the process for 'niaking these in odifiedresins. W

Modifications of the aboveprocedure which have been used for special purposes include warming the acidified mixture before the addition of the beta-propiolactone;acidification and also partial dehydration of. the henol and formaldehyde mix before the beta-propiolactone addition, acidification and dehydration of the said mix to increased viscosity before the lactone addition, and acidification and dehydration to the selected condition of viscosity before the betaprop-iolaotone addition followed by a secondary dehydration after the addition.

SoLIoRnsINs I To makethe solid or more completely modified resinous composition, a large proportion of the lactone and of alkali are used. Examples of suitable proportions are 1 mol each .of sodium hydroxide and beta-propiolactone for each mol of phenol. In this making of the solid material, I may also introduce an added electrolyte such as sodium chloride or other knownelectrolytic precipitant of resins of this general class from solution, to aid precipitation of the modified resin from solution. a

The invention will be further illustrated by description inconnection with the following specific examples of the making of solid resins, the mix used being tabluated.

Example! Phenol 94.1 1gms. (1.00 mol) Formaldehyde (36.4% by wt. aqueous, solution,

methanol-free) 191.42 .gms. (2.32 mol) Sodium hydroxide 11.29 gms. (0.071 mol) .This mix is heated to ref-luxandcondensed for fifteen minutes at reflux temperature. Ag'olden yellow, clear solution isformed. This is cooled to 20 C. and diluted with 941.1 gms. (52.2 mols) of Water. The solution becomes cloudy. 176 gms. (1.10 mol) of 25% by weight aqueous solution of sodium hydroxideare'added with stirring and cooling, the temperature being held at 20 c.

79.2 gms. (1.09 mol) of beta-propiolactone' are pressure" 10 thengradually introduced, the temperatureagain being held at approximately20 C. Cloudingbei i tnt r ii rw i e x3 f t balsam-r0- piolactone'hasbjeefiadded. The product is very milkyfand White but. still alkaline to litmus. This is"acidifiedjwithllllems. (1 21 mol). of formic acid solutionj(50% by weightin water) and the precipitate allowed to settle. The precipitate is ollectedon a fil 'er, washed, and dri'ed.

Theproductis"a"white powder. The yield of it is'65 based on theweight of reactants.

Example 2 Phenol 94.11 gms. (1.0 mol) Formaldehyde (36.4% by vwt. aqueous solu- .tion) 99.00 gms. (1.2 mol) Water f 92.41 gms. (5.13 mol) Sodium hydroxide (255% by wt. aqueous solution) 11.29 gms. (0.071 mol) This 'm X, is cjondensed at reflux for thirty minutes andthentreatedin a similar manner to thatdesoribed in Example 1. The yield of crude creamy powder was roughly 100 Example 3 p,p'Dihydroxy diphenyl pro.- 1

, pane 228.30 gms. (1.00 mol) Formaldehyde (36.4% bywt. aqueous solution methanolfree') 300.90 'gms. (3.65 mol) Water 75.22 gms. (4.17 mol) Sodium hydroxide 22.57 gms. (0.14 mol) Thesefarelmixedjheated to refluxand condensed at ieeu x for 7 minutes. The yellow, practically clear solution resulting therefrom (which clouds upon cooling) is 'testedfor free formaldehyde (314%). 1v;2'egms. o.24mo1 of beta-propiolactone areadded and the sample refluxed another 3 minutes, acidified with 18.97 gms. (0.11 mol) of lactic acid (51% by wt. aqueous solution). The sample, now' cloudy, is'dehydrated at 80 C. under reduced lp're'ssure until no bubbling is observed when the pressureis raised to 40 mms. The sample is thendehydratedan additional ten minutes and'pour ed (yield"2.2l). The yellow, clear liquid of normal pouring viscosity yields a yellow, heavily translucentcasting of hardness +50. A similar sample, unmodified by beta propiolatttone, could not be poured (yield 1.96).

ucts made therefrom. I

these. examples also the composition of the mixes used are tabulated.

remain Bhenol;;.;' ,,94.11 gins. (1.00 mol) 3'7 7Z;,."by Wt. aqueous solution con g. methanol as stabi 1izer 188.22 gms. (2.3211101) Sodium hydroxide solution (25% by Wt.) .'1' ;L 11.29 gms. (0.07 11101) These are mixedjheated to reflux, and refluxed seventeen minutes. Refiuxis then discontinued and 12.97 g s. (0.18 mol) of beta-propiolactone introduced into the clear "yellow solution. The sample is again refluxed one minute followedby ee lm' eroenrtemperature. W I, r

he" resulting solution is water-white, clear and possessesja pH of 5.35. Thlsis placed in a waterd dehydrated under reduced er j bubbling is Q obs rved when theprssure 40 mm. The yield (grams 11 of product per gram of phenol employed initially) is 1.92.

The thin, Water-white, clear liquid is poured into a glass mold and subjected to a cure of fortytwo hours at 90 C. The casting thus formed upon removal from the mold is white, very heavily translucent, and of Rockwell hardness +35.

When the beta-propiolactone in the above preparation is replaced by 8.62 gms. (0.096 mol) of lactic acid, a water-white, clear liquid (yield 1.80) is obtained, the viscosity of which is considered normal for comparison and this upon curing forty-two hours at 90 C. forms a white, opaque casting of a hardness +43.

Example A mix of the same composition as Example 4 is heated to reflux and condensed at reflux for seventeen minutes. At the end of this time, it is modified with 17.29 gms. (0.24 mol) of beta-propiolactone and again refluxed one minute. It is then cooled to room temperature-and a pH adjusted to 4.30 by the addition of a 51% by weight aqueous solution of lactic acid. The sample is then dehydrated until a constant yield (1.96) is obtained and the slightly thin, water-white, clear liquid poured into a glass mold and cured for forty-seven hours at 90 C. A lightly opaque, white casting of hardness +2 is formed.

' Example 6 A mix of the same composition as Example 4 is heated to reflux and condensed at reflux for seventeen minutes. This is then acidified with 8.62 gms. (0.096 mol) of lactic acid (added in the form of a 51% by weight aqueous solution) and dehydrated at 80 C. under reduced pressure until rapid onset in viscosity begins (corresponds to approximately no bubbling when pressure is raised to 50 mms.) and then for twenty minutes longer. At this point 30.27 gms. (0.42 mol) of beta-propiolactone are mixed intimately with the liquid and the sample subjected to an additional five minutes dehydration. The thin, water-white, clear liquid (yield 2.0) thus obtained is poured into a glass mold and cured for fifty hours at 90 C. A white, lightly translucent casting results. (Hardness 9.)

Example 7 A mix of the composition of Example 4 is heated to reflux and condensed at reflux for seventeen minutes. This is acidified immediately to a pH of 4.5 with lactic acid solution (1.12 specific gravity) and dehydrated at 80 C. under reduced pressure until the yield becomes constant (1.78) at this point 4.32 gms. (0.06 mol) of beta-propiolactone is mixed in and the sample again dehydrated for fifteen minutes (yield 1.82). The slightly thin, water-white, clear liquid is poured into a glass mold and cured forty-two hours at 90 C. A white (blue tint), opaque casting results. (Hardness +49.)

Example 8 12 which point 28.2 ml. of a titanium dioxide paste in glycerine is addedand the dehydration is then continued. When no bubbling is observed at 40 mm. at C., the dehydration is stopped. 64.85 gms. (0.90 mol) of beta-propiolactone is mixed in and the water-thin, milky white sample thus formed (yield 2.5) is poured into a mold. The sample is then cured seventy-two hours at C. The resulting casting is White, opaque, extremely soft and displays better'stability to lightthan a similar sample unmodified with beta-propiolactone.

Example 9 A mix of the composition of Example 4 is heated to reflux, condensed seventeen minutes at reflux and treated with 19.46 gms. (0.27 mol) of beta-propiolactone. The sample is then refluxed one minute, cooled to room temperature and the pH measured (pl-I 5.07) 12.6 gms. (0.14 mol) of glycerine is then added at this point and the sample dehydrated at 80 C. until no bubbling is observed when the pressure is made 40 mm. at 80 C. The very thin, water-white, clear liquid (yield 1.98) is poured into a glass mold and cured for forty-two hours at 90 C. The finished casting is water-white, transparent (slight haze), and has a hardness of +39.

1 Example 10 Phenol 94.11 gms. (1.00 mol) Formaldehyde (35.2% by wt. aqueous solution, methanol-free) 188.22 gms. (2.21 mols) Sodium hydroxide (25% by wt. aqueous solution) -1 11.29 gms. (0.07 mol) These are mixed, heated to reflux, and condensed at reflux for twenty-one minutes. The heat is removed and 43.24 gms. (0.60 mol) of beta-propiolactone are added through the top of the condenser at a rate just sutficient to maintain reflux. (Total reflux time seventeen minutes.) The sample is then cooled and 2.15 gms. (0.024 mol) lactic acid added and the sample dehydrated under reduced pressure at 80 C. until no bubbling is observed when the pressure is raised to 40 mm. (yield 2.15). The slightly thin, water-white, clear liquid thus obtained is poured into a mold and cured for sixty-two hours at 90 C. A transparent casting of hardness +17 results. This casting displays a definite haze.

Example .11

Phenol 94.11 gms. (1.00 mol) Formaldehyde (35.2% by wt. aqueous solution, methanol-free) 188.22 gms. (2.21 mol) Sodium hydroxide (25% by wt. aqueous solution) 11.29 gms. (0.07 mol) is transparent (with a definite haze) and possesses a hardness of +57.

, Example 12 Phenol 94.11 gms. (1.00 mol) Formaldehyde (36.4% by wt. aqueous solution,

methanol-free) ;.l08.22 gms; (2.2$ 101) Sodium hydroxide (25%. by wt .aque ous solution) 11.29gmsl (0.0711101) wt. aqueous solution) are then added and the sample dehydrated under reduceiipreSsure at 80 C. until no bubbling is' observed when the pressure is raised to 40mm. A water-white,

clear liquid (yield 1.96) is 'obtained'which is just pourable. Upon curing five days at '75" C. a water-white, transparent (very 1 definite haze) casting of +13 hardness is produced.

' Example 13 Phenol 94.11 "gms. (1.00 mol) Formaldehyde (36.4% by wt. aqueous'solution, methanol-free) 188 .22g ms.'(2.28 mol) Sodium hydroxide (25% by wt. aqueous solution) 11.29 gms. (0.07 mol) Methanol 33.88 gms. (1.06 mol) These are mixed, heated to reflux and condensed at reflux for twenty minutes. The sample is cooled to room temperature at this pointand 19.01 gms. (0.48 mol) of sodium hydroxide added (in form of 25% by wt. aqueous solution). The deep yellow, clear solution originating is then treated with 34.59 gms. (0.48 mol) of beta-propiolactone, the latter being added slowly with stirring and the temperature beinghld at room" temperature by cooling. 'An.ol1 -white suspension results. The addition of 18128 gms. (0.20

mol) of lactic acid causes separation (color now white, pH 5.6). .This is dehydrated at 80 C. under reduced pressure and thesa'r'nplegradually clears during this step. When it becomes slightly thin-normal in viscosity. (yield 2.42) the offwhite clear liquid is p'o'uredinto a'glassmold and cured for 40 hours at 90 C. The casting is orange brown, translucent, and possesses a hardness at +43. Asample similarly prepared without the secondary caustic addition and acidified I with 8.60 gms. (0.096 mol) of lactic acid (pH 4.7)

yields a, white, opaque casting (hardness +48).

Ewarnplelai A mix of the composition of Example 12 is heated to reflux and condensed fifteen minutes at re- The heat is removed and*17.29"gms.' (0.24 mol) of beta-propiolactone is added at a rate to just maintain reflux and refluxing continued for a total of eighteen minutes. The mix is then acidified with 12.23 gms. (0.080 mol) of mandelic acid and dehydrated until no bubbling is observed at 40 mm. and 80 C. The Water-white, clear, slightly thin to thin liquid (yield 1.99) is poured into a glass mold and cured for 1 day at 90 C. The casting is water-white, transparent and possesses a hardness of -9.

Example 15 A preparation similar to Example 14 is made in which the mandelic acid is replaced by 14.12 gms. (0.079 mol) of hippuric acid. The liquid at pour is thin to slightly thin and the yield 2.01.

debates The ass-11gistinted'iiinkjis tiaiisiiarentfand exhibits a hardness of +24.

Example '16 A preparation similar to l l' i's which the mandelic'a'cfid is replacedfy'10.54'gms. (0.081 mol) of itaconic acid. 1 1i" idisfthin to slightly thin at-pour and the yield is 1.97,?The

' casting formed is water-white, li'g htlyopa'que and has a hardness of +14.

Example 17 I Phenol 9451'1gms. (100mol) Formaldehyde (36.7 I by"-wt."aqeoi1s solution, methanol-free) 188.22 gms2 '(2;28 mol) Benzyl trimethyl ammo'niuin hydroxide (19.14% in phenol solution) 51.43 gms. (0.59 mol) waterwhite, clear and very thin. The casting is water-white, transparent (definite haze), and

possesses a hardness -'of +31 after a cure of 40 hrs. at 90 C. -,A sample unmodified with betapropiolactone yields a f #1 1 1] to' slightly 'thinj liquid which forms an jofi-c'o'lore'dj*heavily translucent casting of +25 hardness (yield1'.73).

Example pane 223.28 gms. (1.00 mol) Formaldehyde (36.4%by"wtfaqueous solution,

methanol-free) 300.86 gms. (3.65 mol) Sodium hydroxide (25%,,by wt., aqueoussolu- These are I mixedf heated; reflux and con.

densed at reflux for seven-minutes; .Theyellow,

practically clear solution resulting therefrom (which clouds upon cooling) is tested for free formaldehyde (3.4%). .1729 gms. (0 24 mol) of beta-pi opiola'ctone are added and ifthjef' sample refluxed another three minutes. 'Thesys'tem is acidified with 18.97 'gmsi (011'1 mol)-"or lactic acid (51% by Wt. aqueoussolution) and the sample,

now cloudy, dehydrated" at "80 ?C1j'u'rider reduced pressure untn'notpubblnig isobservjedfwh'en the pressure is raised to' ro inm.",The"sample is" then dehydrated an additionalten'minute's and poured (yield 2.21). The yellowfclear liquidof normal pouring viscosity yields a yellow, heavily translucent casting of hardness +50. A similar sample unmodified by beta-propiolactone, could not be poured (yield 1.96).

Ezcample 19 Resorcinol 110.11 gms. (1.00 mol) Water 17.30 gms. (0.96 mol) Methanol 48.00 gms. (1.50 mol) Sodium hydroxide (25% by wt. aqueous solution) 8.00 gms. (0.05 mol) These are mixed and heated to reflux at which point 48.7 gms. (0.60 mol) of 37% by Wt. aqueous solution of formaldehyde (containing methanol stabilizer) are added, the addition being made over a period of 5-10 minutes. The reflux is continued after the formaldehyde addition has been completed until sixty minutes have elapsed from the start of reflux. The heating is then discontinued and 36.03 gms. (0.50 mol) of beta-propiolactone added at a rate just sufficient to maintain reflux and the reflux continued after this addition until a total reflux time of sixty-seven minutes is noted. The product is a brown solution, immiscible with further water, of pH 4.3.

I The addition to this solution of paraform in amount to raise the resorcinol-iormaldehyde ratio to 111.3 produces a composition which does not gel within a period of one week at room temperature; a sample, unmodified with beta-propiolactone treated in an analogous manner gels in 8 hours.

Example 20 Phenol 94=.11 gms. (1.00 mol) Furfural 120.10 gms. (1.25 mol) Sodium hydroxide (20% by Wt. aqueous solution) 12.00 gms. (0.06 mol) The mix is condensed for 145 minutes at 110- 115 C. At the end of this period 36.03 gms. (0.5 mol) of beta-propiolactone are added and the sample again heated at 110-115 C. for 20 minutes (pl-I 5.4). Separation occurs upon cooling. The resin layer is much thinner in viscosity than that from an unmodified sample (pH 9.7).

MooirroArroivs or ABOVE EXAMPLES Example 21 The method of any of the Examples 1-20 is repeated except that the phenol used is any one or a mixture of any selected from the group consisting of phenol, cresol, xylenol, guaiacol, p,pdihydroxydiphenylpropane, p,pdihy d r o x y d iphenyl, and 1,5-dihydroxynaphthalene. The selected phenol is used in proportion chemically equivalent to the phenol replaced.

Example 22 Phenol-aldehyde resins in which the usual formaldehyde reagent has been replaced by paraform, trioxane, hexamethylene tetramine, glyoxal, acetaldehyde or furfural may be modified by beta-propiolacetone as set forth in Examples 1-19 and 21.

Example 23 l6 1. In a modification the proportion of the polyhydric alcohol is made 1 to 2 equivalents for each carboxyl group in the resin. Esters result.

The finished esters are solid or viscous products suitable for use as varnish and paint making resins.

In a modification, the procedure of this example is repeated except that the polyhydric alcohol is esterified with the lactone modified product that is made as described in any of the examples above and is in uncured condition.

Example 24 The procedure of any of the Examples 1-23 is followed except that the lactone there used is replaced by an equivalent proportion of betabutyrolactone or beta-isobutyrolactone or a mixture of them with each other or of either or both of them with beta-propiolactone.

It will be understood that it is intended to cover all changes and modifications of the examples of the invention herein shown for the purpose of illustration which do not constitute departures from the spirit and scope of the invention.

What I claim is:

1. In making a resinous composition, the method which comprises maintaining phenol in contact with formaldehyde, in the proportion of approximately 0.8 to 2.5 mols for 1 mol of the phenol, alkali and water, until condensation occurs to give a water soluble condensation product and until the content of free formaldehyde ceases to fall rapidly; then introducing into the resulting water soluble condensation product a lactone selected from the group consisting of beta-propiolactone, beta-butyrolactone, and beta-isobutyrolactone, in the proportion of 0.1 to 1 mol of the lactone for 1 mol of the phenol used, and a water soluble alkali in amount if any required to establish the pH of the resulting mixture at a level at least as high as 4; introducing the said alkali in additional amount if any required from time to time to maintain the pH at the said level; and continuing the contact of the said condensation product, lactone and alkali until reaction in the mixture practically ceases.

2. The method of claim 1 in which the lactone used is beta-propiolactone.

439,962 Germany Jan. 20, 1927 

1. IN MAKING A RESINOUS COMPOSITION, THE METHOD WHICH COMPRISES MAINTAINING PHENOL IN CONTACT WITH FORMALDEHYDE, IN THE PROPORTION OF APPROXIMATELY 0.8 TO 2.5 MOLS FOR 1 MOL OF THE PHENOL, ALKALI AND WATER, UNTIL CONDENSATION OCCURS TO GIVE A WATER SOLUBLE CONDENSATION PRODUCT AND UNTIL THE CONTANT OF FREE FORMALDEHYDE CEASES TO FALL RAPIDLY; THEN INTRODUCING INTO THE RESULTING WATER SOLUBLE CONDENSATION PRODUCT A LACTONE SELECTED FROM THE GROUP CONSISTING OF BETA-PROPIOLACTONE, BETA-BUTYROLACTONE, AND BETA-ISOBUTYROLACTONE, IN THE PROPORTION OF 0.1 TO 1 MOL OF THE LACTONE FOR 1 MOL OF THE PHENOL USED, AND A WATER SOLUBLE ALKALI IN AMOUN TIF ANY REQUIRED TO ''ESTABLISH THE PH OF THE RESULTING MIXTURE AT A LEVEL AT LEAST AS HIGH AS 4; INTRODUCING THE SAID ALKALI IN ADDITIONAL AMOUNT IF ANY REQUIRED FROM TIME TO TIME TO MAINTAIN THE PH AT THE SAID LEVEL; AND CONTINUING THE CONTACT OF THE SAID CONDENSATION PRODUCT, LACTONE AND ALKALI UNTIL REACTION IN THE MIXTURE PRACTICALLY CEASES. 